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Hybrid Propulsion Technology

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Hybrid Propulsion Technology Hybrid propulsion technology Marine Propulsion Systems 2 3 David and Goliath: Instead of working against each other, small tugs and huge cargo container ships work together. The latter are irreplaceable for the global transport of goods and cover long distances in demanding seas. But when it comes to manoeuvring in the port area, the steel giants are de- pendent on the help of “tuggers”. Neptune’s new EuroTug 3515 is one of them. Since robustness and performance are particularly important here, the Dutch shipyard relies on ZF technology, the hybrid-capable ZF W5355 PTI transmission Combining the best of two worlds In view of increasingly stringent regula- tions on the high seas and in port cities, the future of shipping belongs to clean and sustainable propulsion systems. ZF’s comprehensive hybrid portfolio is designed to expanding its gearboxes with an clutchable additional Application-oriented help reduce emissions, fuel consumption and operat- power take-in (PTI), via which an electric machine hybrid concepts ing costs. This next generation technology will support alone or in conjunction with the conventional power shipbuilders, vessel owners, and operators in many unit drives the propeller shaft. This auxiliary drive can PTI equipped ZF transmissions allow for various CODAE / Combined Diesel and Electric application segments worldwide. The Group offers serve a variety of ratios. An optional spur gear compen- hybrid concepts in marine applications. Not only transmissions, electric motors, converters and control sates for differences in speed between the main engine the future-oriented combination with an electric mo- Diesel Engine systems from a single source, which further increases and the electric motor. tor is possible, but also the connection of a conven- Hybrid Ready Main Engine reliability, efficiency and quality. tional internal combustion engine, which may be Transmission There are many arguments in favor of maritime hybrid the more appropriate solution for some applications. Propeller propulsion systems: less noise and exhaust gases, but Advantages for almost all ship types Thus, two powerful main engines can be connected more fuel savings and more effective power delivery for maximum performance. Alternatively, a smaller during slow speed maneuvering. Starting in 2020, The portfolio of hybrid systems covers a power range internal combustion engine is installed as an Electric Motor PTI stricter environmental regulations and laws apply from approximately 600 kW of conventional power auxiliary unit to increase performance or as a more (Auxiliary) (clutchable) to the oceans. In electric mode, hybrid vessels may (ZF 33X0 series) to a maximum of 11,500 kW economical drive for low-load operation. continue to drive to ports and waters that are closed (ZF 83700). In the lower power range, the hybrid- to purely conventional vessels. Manufacturers and ready transmissions can be combined with electric operators alike benefit from the broad portfolio of motors and converters between 150 kWe and 750 kWe. hybrid-ready transmissions that ZF offers for almost Thus, ZF offers suitable propulsion solutions for a large all application segments. To this end, the company is number of different marine applications. 4 5 Controls Hybrid technology from one source Thruster Control ZF is expanding its already wide range of hybrid-ready Cabinet marine transmissions with the ZF 5200 PTI as down angle version underlines the claim of being a complete Transmission (hybrid) driveline supplier. Electric Motor Emission-free power ZF 5200 PTI transmission with down angle Fixed Pitch Propeller The electric drives offered by ZF enable shipbuilders to With the ZF 5200 PTI transmission, ZF is presenting the and Shaftline pursue a hybrid platform strategy for the driveline with first downangle transmission ready for hybrid applica- the transmission and electric motor coming from one tions. With this transmission A and V configurations can source. The combination of these two innovative tech- be realized, allowing horizontal installation of engine and nologies in one propulsion system guarantees perfect gearbox giving manufacturers high flexibility for new interaction and optimum power delivery. designs and retrofits. With multiple gear ratios it match- es main engines ranging from 900 to 2500 kW and with Power range of electric motors for PTI transmissions The drive is based on synchronous reluctance assisted the variety of PTI spur gears e-motors up to 450 kWe permanent magnet technology (SRPM) offering undis- can be added. Due to the compact and light design, the Main engine power [kW] → 8,000 7,000 6,000 5,000 4,000 3,000 2,000 1,000 0 puted benefits for the operator: e-motors can be flanged directly to the transmission. Thus the ZF 5200 transmission with PTI covers a wide ZF 837X0 600 kWe 750 kWe • Liquid-cooled for high peak and continuous loading range of applications and can be used in coast guard • Compact design and light weight, allowing retrofit of ships, yachts and commercial vessels. conventional drivelines ZF 43X00 600 kWe 750 kWe • Works as generator for maximum flexibility in the power management Specifications and features ZF 24X60 600 kWe • Certification by all major classification societies • Flexibility to be integrated into a wide variety of hybrid • Optimal system performance with ZF PTI-transmis- vessel propulsion solutions ZF 11XX0 450 kWe 600 kWe sions, inverters and electronics • Rated up to 2,500 kW • Zero-emission driving in fully electrical mode • Gear ratios from 2.588 to 4.250 • Incl. PTI ratio with spur gear up to 13.81 ZF 10XX0 450 kWe 600 kWe • Configurable to various applications in the appropriate series Transmssion power range, for both super yachts and commercial ZF 93X0 300 kWe 450 kWe 600 kWe vessels • Top, live, and pump PTO available, as well as optional 300 kWe 450 kWe trailing pumps ZF 83X0 • The ZF 5200 PTI, like all ZF marine transmissions, can be certified by all major classification societies ZF 5XX0 150 300 kWe 450 kWe ZF 33X0 150 300 kWe 0 200 400 600 ← Electric engine power [kWe] Gearbox Gearbox Generator Generator E-Motor E-Motor Main Engine Main Engine Hotel Load Hotel Load Battery Battery Inverter Inverter Gearbox Gearbox Generator Generator E-Motor E-Motor 6 Main Engine 7 Main Engine Operation modes with electric motor Engines can be operated in different modes depending on priorities. DIESEL DRIVE MODE Gearbox Gearbox Generator Generator E-Motor E-Motor • E-Motor off Main Engine Main Engine • Propulsion by main engine (diesel) Hotel Load Hotel Load Battery Battery • Hotel load by main generator or battery* Inverter Inverter Gearbox Gearbox Generator Generator E-Motor E-Motor Main Engine Main Engine ELECTRIC DRIVE MODE Gearbox Gearbox Generator Generator Hybrid pays off E-Motor E-Motor • Main engine (diesel) off Main Engine Main Engine Hotel Load Hotel Load • Propulsion by E-motor Battery Battery • Powered by main generator or battery* Inverter Inverter for everyone • Hotel load by main generator or battery* Gearbox Gearbox Generator Generator E-Motor E-Motor Main Engine Main Engine Various options for hybrid operation ensure that vessels are capable of balancing economic benefits, performance, and protection of the environment. BOOST MODEGearbox Gearbox Gearbox Generator Generator Generator • MainE-Motor engine (diesel) on E-Motor E-Motor • Main generator onMain Engine Main EngineEngine Main Engine Hotel Load Hotel Load Hotel Load • Propulsion by E-motorBattery and main engine (diesel) Battery Battery When adapted to the application, the intelligent use of • Powered by main generator or battery*Inverter Inverter Inverter different hybrid operation modes allows the best pos- • Hotel loadG earboby mainx generator or battery* Gearbox Gearbox Generator Generator Generator sible consideration of different, sometimes conflicting Generator Generator Generator E-Motor E-Mot-Motor E-Motor interests for different ship types. Thus, the economic Main Engine Main EngineEngine Main Engine Hotel Load Hotel Load Hotel Load aspects of the operator can be optimally combined with Battery Battery Battery legal regulations regarding exhaust and noise emissions Inverter Inverter Inverter as well as the power requirements of the application in Gearbox Gearbox Gearbox operation. Generator Generator Generator For example, harbor tugboats can be operated fuel-opti- E-Motor E-Motor E-Motor GENERATOR MODEMain Engine Main EngineEngine Main Engine mized in stand-by mode, ferries and motor yachts can be Gearbox Gearbox Generator Generator run purely electrically, and research vessels are maneu- • Main engine (diesel) on E-Motor E-Motor vered virtually silently and with low vibration. Since the • Propulsion by mainMain Engine engine (diesel) Main Engine Hotel Load Hotel Load main engine is offline in Electrical Drive Mode, operating • E-motor as generatorBattery driven by main engine Battery hours are saved. This increases the life of the unit and • Main generator only switched on if additional Gearbox Inverter Gearbox Inverter Gearbox reduces operating costs as maintenance intervals can load of battery*Gearbox or hotel loadGener isat requiredor Gearbox Generator Generator be further extended. The electric motor also allows for E-Motor Generator E-Motor Generator E-Motor two more modes of operation. In addition to the purely E-Motor Main Engine E-Motor Main EngineEngine Main Engine Main Engine Hotel Load Main Engine Hotel Load Hotel Load electric or conventional mode, the electric power unit Battery Battery Battery can be used as a boost when accelerating or – in gen- Inverter Inverter Inverter erator mode – to cover the electric power requirements Gearbox Gearbox Gearbox Generator Generator on board of the ship. This allows for further fuel savings. RECUPERATION MODE (energyGenerat harvestingor while under sail) available for sailboats Generator Generator E-Motor E-Motor E-Motor Residents of port cities benefit from reduced noise and Main Engine Main EnginEnginee Main Engine Hotel Load Hotel Load emission levels, as does aquatic life. All the while, the * if battery availableBatt ery(Diesel engine, main generator, power management andB attbattery)ery not ZF scope of supply.
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